Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
  • D04C1/00—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof
  • D04C1/06—Braid or lace serving particular purposes
  • D04C1/12—Cords, lines, or tows
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
  • D04C3/00—Braiding or lacing machines
  • D04C3/40—Braiding or lacing machines for making tubular braids by circulating strand supplies around braiding centre at equal distances
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
  • D04C1/00—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof
  • D04C1/06—Braid or lace serving particular purposes
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
  • D04C3/00—Braiding or lacing machines
  • D04C3/40—Braiding or lacing machines for making tubular braids by circulating strand supplies around braiding centre at equal distances
  • D04C3/44—Braiding or lacing machines for making tubular braids by circulating strand supplies around braiding centre at equal distances with means for forming sheds by subsequently diverting various threads using the same guiding means
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
  • D04C3/00—Braiding or lacing machines
  • D04C3/48—Auxiliary devices
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2509/00—Medical; Hygiene
  • D10B2509/06—Vascular grafts; stents

Definitions

• the present technology relates generally to systems and methods for forming a tubular braid of filaments.
• some embodiments of the present technology relate to systems for forming a braid through the movement of vertical tubes, each housing a filament, in a series of discrete radial and arcuate paths around a longitudinal axis of a mandrel.
• Braids generally comprise many filaments interwoven together to form a cylindrical or otherwise tubular structure.
• Such braids have a wide array of medical applications.
• braids can be designed to collapse into small catheters for deployment in minimally invasive surgical procedures. Once deployed from a catheter, some braids can expand within the vessel or other bodily lumen in which they are deployed to, for example, occlude or slow the flow of bodily fluids, to trap or filter particles within a bodily fluid, or to retrieve blood clots or other foreign objects in the body.
• Some known machines for forming braids operate by moving spools of wire such that the wires paid out from individual spools cross over/under one another.
• these braiding machines are not suitable for most medical applications that require braids constructed of very fine wires that have a low tensile strength.
• the wires are paid out from the spools they can be subject to large impulse forces that may break the wires.
• Other known braiding machines secure a weight to each wire to tension the wires without subjecting them to large impulse forces during the braiding process. These machines then manipulate the wires using hooks other means for gripping the wires to braid the wires over/under each other.
• One drawback with such braiding machines is that they tend to be very slow.
• braids have many applications, the specifications of their design—such as their length, diameter, pore size, etc., can vary greatly. Accordingly, it would be desirable to provide a braiding machine capable of forming braids with varying dimensions, using very thin filaments, and at higher speeds that hook-type over/under braiders.
• Figure 1 is an isometric view of a braiding system configured in accordance with embodiments of the present technology.
• Figure 2 is an enlarged cross-sectional view of a tube of the braiding system shown in Figure 1 configured in accordance with embodiments of the present technology.
• Figure 3 is an isometric view of an upper drive unit of the braiding system shown in Figure 1 configured in accordance with embodiments of the present technology.
• Figure 4A is a top view
• Figure 4B is an enlarged top view, of an outer assembly of the upper drive unit shown in Figure 3 configured in accordance with embodiments of the present technology.
• Figure 5 is a top view of an inner assembly of the upper drive unit shown in Figure 3 configured in accordance with embodiments of the present technology.
• Figure 6 is an enlarged isometric view of a portion of the upper drive unit shown in Figure 3 configured in accordance with embodiments of the present technology.
• Figure 7 is an isometric view of a lower drive unit of the braiding system shown in Figure 1 configured in accordance with embodiments of the present technology.
• Figures 8A-8H are enlarged, schematic views of the upper drive unit shown in Figure 3 at various stages in a method of forming a braided structure in accordance with embodiments of the present technology.
• Figure 9 is a display of user interface for a braiding system controller configured in accordance with embodiments of the present technology.
• Figure 10 is an isometric of a portion of a mandrel of the braiding system shown in Figure 1 configured in accordance with embodiments of the present technology.
• a braiding system can include an upper drive unit, a lower drive unit coaxially aligned with the upper drive unit along a central axis, and a plurality of tubes extending between the upper and lower drive units and constrained within the upper and lower drive units.
• Each tube can receive the end of an individual filament attached to a weight.
• the filaments can extend from the tubes to a mandrel aligned with the central axis.
• the upper and lower drive units can act in synchronization to move a subset of the tubes (i) radially inward toward the central axis, (ii) radially outward from the central axis, (iii) and rotationally about the central axis. Accordingly, the upper and lower drive units can operate to move the subset of tubes— and the filaments held therein— past another subset of tubes to form, for example, an "over/under" braided structure on the mandrel. Because the wires are contained within the tubes and the upper and lower drive units act in synchronization upon both the upper and lower portion of the tubes, the tubes can be rapidly moved past each other to form the braid.
• the terms “vertical,” “lateral,” “upper,” and “lower” can refer to relative directions or positions of features in the braiding systems in view of the orientation shown in the Figures.
• “upper” or “uppermost” can refer to a feature positioned closer to the top of a page than another feature.
• These terms should be construed broadly to include semiconductor devices having other orientations, such as inverted or inclined orientations where top/bottom, over/under, above/below, up/down, and left/right can be interchanged depending on the orientation.
• FIG 1 is an isometric of a braiding system 100 (“system 100") configured in accordance with the present technology.
• the system 100 includes a frame 1 10, an upper drive unit 120 coupled to the frame 1 10, a lower drive unit 130 coupled to the frame 110, a plurality of tubes 140 (e.g., elongate housings) extending between the upper and lower drive units 120, 130 (collectively "drive units 120, 130"), and a mandrel 102.
• the drive units 120, 130 and the mandrel 102 are coaxially aligned along a central axis L (e.g., a longitudinal axis).
• the tubes 140 are arranged symmetrically with respect to the central axis L with their longitudinal axes parallel to the central axis L. As shown, the tubes 140 are arranged in a circular array about the central axis L. That is, the tubes 140 can each be spaced equally radially from the central axis L, and can collectively form a cylindrical shape. In other embodiments, the longitudinal axes of the tubes 140 may not be vertically aligned with (e.g., parallel to) the central axis L. For example, the tubes 140 can be arranged in a conical shape such that the longitudinal axes of the tubes 140 are angled with respect to and intersect the central axis L.
• the tubes 140 can be arranged in a "twisted" shape in which the longitudinal axes of the tubes 140 are angled with respect to the central axis L, but do not intersect the central axis L (e.g., the top ends of the tubes can be angularly offset from the bottom ends of the tubes with respect the central axis L).
• the frame 1 10 can generally comprise a metal (e.g., steel, aluminum, etc.) structure for supporting and housing the components of the system 100. More particularly, for example, the frame 1 10 can include an upper support structure 116 that supports the upper drive unit 120, a lower support structure 118 that supports the lower drive unit 130, a base 1 12, and a top 114. In some embodiments, the drive units 120, 130 are directly attached (e.g., via bolts, screws, etc.) to the upper and lower support structures 116, 1 18, respectively. In some embodiments, the base 1 12 can be configured to support all or a portion of the tubes 140.
• a metal e.g., steel, aluminum, etc.
• the system 100 includes wheels 1 11 coupled to the base 112 of the frame 110 and can, accordingly, be a portable system.
• the base 1 12 can be permanently attached to a surface (e.g., a floor) such that the system 100 is not portable.
• the system 100 operates to braid filaments 104 loaded to extend radially from the mandrel 102 to the tubes 140.
• each tube 140 can receive a single filament 104 therein.
• only a subset of the tubes 140 receive a filament.
• the total number of filaments 104 is one half the total number of tubes 140 that house the filament 104s. That is, the same filament 104 can have two ends, and two different tubes 140 can receive the different ends of the same filament 104 (e.g., after the filament 104 has been wrapped around or otherwise secured to the mandrel 102).
• the total number of filaments 104 is the same as the number of tubes 140 that house a filament 104.
• each filament 104 is tensioned by a weight secured to a lower portion of the filament 104.
• Figure 2 is an enlarged cross-sectional view of an individual tube 140.
• the filament 104 includes an end portion 207 coupled to (e.g., tied to, wrapped around, etc.) a weight 241 positioned within the tube 140.
• the weight 141 can have a cylindrical or other shape and is configured to slide smoothly within the tube 140 as the filament 104 is paid out during the braiding process.
• the tubes 140 can further include an upper edge portion (e.g., rim) 245 that is rounded or otherwise configured to permit the filament 104 to smoothly pay out from the tube 140.
• the tubes 140 have a circular cross-sectional shape, and completely enclose the weights 241 and the filaments 104 disposed therein.
• the tubes 140 may have other cross-sectional shapes, such as square, rectangular, oval, polygonal, etc., and may not completely enclose or surround the weights 241 and/or the filaments 104.
• the tubes 140 may include slots, openings, and/or other features while still providing the necessary housing and restraint of the filaments 104.
• the tubes 140 constrain lateral or "swinging" movement of the weights 241 and filaments 104 to inhibit significant swaying and tangling of these components along the full length of the filaments 104.
• This enables the system 100 to operate at higher speeds compared to systems in which filaments and/or tensioning means are non-constrained along their full lengths.
• filaments that are not constrained may sway and get tangled with each other if a pause or dwell time is not incorporated into the process so that the filaments can settle.
• the filaments 104 are very fine wires that would otherwise require significant pauses for settling without the full-length constraint and synchronization of the present technology.
• the filaments 104 are all coupled to identical weights to provide for uniform tensions within the system 100. However, in other embodiments, some or all of the filaments 104 can be coupled to different weights to provide different tensions. Notably, the weights 241 may be made very small to apply a low tension on the filaments 104 and thus allow for the braiding of fine (e.g., small diameter) and fragile filaments.
• the drive units 120, 130 control the movement and location of the tubes 140.
• the drive units 120, 130 are configured to drive the tubes 140 in a series of discrete radial and arcuate paths relative to the central axis L that move the filaments 104 in a manner that forms a braided structure 105 (e.g., a woven tubular braid; "braid 105") on the mandrel 102.
• the tubes 140 each have an upper end portion 142 proximate the upper drive unit 120 and a lower end portion 144 proximate the lower drive unit 130.
• the drive units 120, 130 work in synchronization to simultaneously drive the upper end portion 142 and the lower end portion 144 (collectively "end portions 142, 144") of each individual tube 140 along the same path or at least a substantially similar spatial path.
• end portions 142, 144 By driving both end portions 142, 144 of the individual tubes 140 in synchronization, the amount of sway or other undesirable movement of the tubes 140 is highly limited.
• the system 100 reduces or even eliminates pauses during the braiding process to allow the tubes to settle, which enables the system 100 to be operated at higher speeds than conventional systems.
• the drive units 120, 130 can be arranged differently with respect to the tubes 130.
• the drive units 120, 130 can be positioned at two locations that are not adjacent to the end portions 142, 144 of the tubes 140.
• the drive units Preferably, the drive units have a vertical spacing (e.g., arranged close enough to the end portions 142, 144 of the tubes 140) that provides stability to the tubes 140 and inhibit swaying or other unwanted movement of the tubes 140.
• the drive units 120, 130 are substantially identical and include one or more mechanical connections so that they move identically (e.g., in synchronization).
• one of the drive units 120, 130 can be an active unit while the other of the drive units 120, 130 can be a slave unit driven by the active unit.
• an electronic control system coupled to the drive units 120, 130 is configured to move the tubes 140 in an identical sequence, spatially and temporally.
• the drive units 120, 130 can have the same components but with varying diameters.
• the mandrel 102 is attached to a pull mechanism 106 configured to move (e.g., raise) the mandrel 102 along the central axis L relative to the tubes 140.
• the pull mechanism 106 can include a shaft 108 (e.g., a cable, string, rigid structure, etc.) that couples the mandrel 102 to an actuator or motor (not pictured) for moving the mandrel 102.
• the pull mechanism 106 can further include one or more guides 109 (e.g., wheels, pulleys, rollers, etc.) coupled to the frame 110 for guiding the shaft 108 and directing the force from the actuator or motor to the mandrel 102.
• the mandrel 102 can be raised away from the tubes 140 to extend the surface for creating the braid 105 on the mandrel 102.
• the rate at which the mandrel 102 is raised can be varied in order to vary the characteristics of the braid 105 (e.g., to increase or decrease the braid angle (pitch) of the filaments 104 and thus the pore size of the braid 105).
• the ultimate length of the finished braid depends on the available length of the filaments 104 in the tubes 140, the pitch of the braid, and the available length of the mandrel 102.
• the mandrel 102 can have lengthwise grooves along its length to, for example, grip the filaments 104.
• the mandrel 102 can further include components for inhibiting rotation of the mandrel 102 relative to the central axis L during the braiding process.
• the mandrel 102 can include a longitudinal keyway (e.g., channel) and a stationary locking pin slidably received in the keyway that maintains the orientation of the mandrel 102 as it is raised.
• the diameter of the mandrel 102 is limited on the large end only by the dimensions of the drive units 120, 130, and on the small end by the quantities and diameters of the filaments 104 being braided.
• the system 100 can further include one or weights coupled to the mandrel 102.
• the weights can put the mandrel 102 under significant tension and prevent the filaments 104 from deforming the mandrel 102 longitudinally during the braiding process.
• the weights can be configured to further inhibit rotation of the mandrel 102 and/or replace the use of a keyway and locking pin to inhibit rotation.
• the system 100 can further include a bushing (e.g., ring) 117 coupled to the frame 110 via an arm 115.
• the mandrel 102 extends through the bushing 117 and the filaments 104 each extend through an annular opening between the mandrel 102 and the bushing 117.
• the bushing 117 has an inner diameter that is only slightly larger than an outer diameter of the mandrel 102. Therefore, during operation, the bushing 117 forces the filaments 104 against the mandrel 102 such that the braid 105 pulls tightly against the mandrel 102.
• the bushing 117 can have an adjustable inner diameter to accommodate filaments of different diameters.
• FIG 3 is an isometric view of the upper drive unit 120 shown in Figure 1 configured in accordance with embodiments of the present technology.
• the upper drive unit 120 includes an outer assembly 350 and an inner assembly 370 (collectively "assemblies 350, 370") arranged concentrically about the central axis L ( Figure 1).
• the outer assembly 350 includes (i) outer slots (e.g., grooves) 354, (ii) outer drive members (e.g., plungers) 356 aligned with and/or positioned within corresponding outer slots 354, and (iii) an outer drive mechanism configured to move the outer drive members 356 radially inward through the outer slots 354.
• the number of outer slots 354 can be equal to the number of tubes 140 in the system 100, and the outer slots 354 are configured to receive the tubes 140 therein.
• the outer assembly 350 includes 48 outer slots 354.
• the outer assembly 350 can have a different number of outer slots 354 such as 12 slots, 24 slots, 96 slots, or any other preferably even number of slots.
• the outer assembly 350 further includes an upper plate 351 a and a lower plate 351b opposite the upper plate 351 a.
• the upper plate 351a at least partially defines an upper surface of the outer assembly 350.
• the lower plate 351b can be attached to the upper support structure 116 of the frame 110.
• the outer drive mechanism of the outer assembly 350 includes a first outer cam ring 352a and a second outer cam ring 352b (collectively “outer cam rings 352") positioned between the upper and lower plates 351a, 351b.
• a first outer cam ring motor 358a can be an electric motor configured to drive the first outer cam ring 352a to move a first set of the outer drive members 356 radially inward to thereby move a first set of the tubes 140 radially inward.
• a second outer cam ring motor 358b is configured to rotate the second outer cam ring 352b to move a second set of the outer drive members 356 radially inward to thereby move a second set of the tubes 140 radially inward.
• the first outer cam ring motor 358a can be coupled to one or more pinions 357a configured to engage a corresponding first track 359a on the first outer cam ring 352a
• the second outer cam ring motor 358b can be coupled to one or more pinions 357b configured to engage a corresponding second track 359b on the second outer cam ring 352b.
• the first and second tracks 359a, 359b extend only partially around the perimeter of the first and second outer cam rings 352a, 352b respectively. Accordingly, in such embodiments, the outer cam rings 352 are not configured to fully rotate about the central axis L. Rather, the outer cam rings 352 move through only a relatively small arc length (e.g., about l °-5°, or about 5°-10°) about the central axis L. In operation, the outer cam rings 352 can be rotated in a first direction and a second direction (e.g., by reversing the motor) through the relatively small angle. In other embodiments, the tracks 359 extend around a larger portion of the perimeter, such as the entire perimeter, of the outer cam rings 352, and the outer cam rings 352 can be rotated more fully (e.g., entirely) about the central axis L.
• the tracks 359 extend around a larger portion of the perimeter, such as the entire perimeter, of the outer cam rings 352, and the outer cam rings 352 can be rotate
• the inner assembly 370 includes (i) inner slots (e.g., grooves) 374, (ii) inner drive members (e.g., plungers) 376 aligned with and/or positioned within corresponding ones of the inner slots 374, and (iii) an inner drive mechanism configured to move the inner drive members 376 radially outward through the inner slots 374.
• the number of inner slots 374 can be equal to one half the number of outer slots 354 (e.g., 24 inner slots 374) such that the inner slots 374 are configured to receive a subset (e.g., half) of the tubes 140 therein.
• the ratio of outer slots 354 to inner slots 374 can be different in other embodiments, such as one-to-one.
• the inner slots 374 are aligned with alternating ones of the tubes 140 and the outer slots 354 and, as described in further detail below, one of the outer cam rings 352 can be rotated to move the aligned tubes 140 into the inner slots 374.
• the inner assembly 370 can further include a lower plate 371b that is rotatably coupled to an inner support member 373.
• the rotatable coupling comprises a plurality of bearings disposed in a circular groove formed between the inner support member 373 and the lower plate 371b.
• the inner assembly 370 can further include an upper plate 371 a opposite the lower plate 371b and at least partially defining an upper surface of the inner assembly 370.
• the inner drive mechanism comprises an inner cam ring 372 positioned between the upper and lower plates 371a, 371b.
• An inner cam ring motor 378 is configured to drive (e.g., rotate) the inner cam ring 372 to move all of the inner drive members 376 radially outward to thereby move tubes 140 positioned in the inner slots 374 radially outward.
• the inner cam ring motor 378 can be generally similar to the first and second outer cam ring motors 358a, 358b (collectively "outer cam ring motors 358").
• the inner cam ring motor 378 can be coupled to one or more pinions configured to engage (e.g., mate with) a corresponding track on the inner cam ring 372 (obscured in Figure 3; best illustrated in Figure 6).
• the track extends around only a portion of an inner perimeter of the inner cam ring 372, and the inner cam ring motor 378 is rotatable in a first direction and a second opposite direction to drive the inner cam ring 372 through only a relatively small arc length (e.g., about l °-5°, about 5°-10°, or about 10°-20°) about the central axis L.
• the inner assembly 370 further includes an inner assembly motor 375 configured to rotate the inner assembly 370 relative to the outer assembly 350. This rotation allows for the inner slots 374 to be rotated into alignment with different outer slots 354.
• the operation of the inner assembly motor 375 can be generally similar to that of the outer cam ring motors 358 and the inner cam ring motor 378.
• the inner assembly motor 375 can rotate one or more pinions coupled to a track mounted on the lower plate 371b and/or the upper plate 371 a.
• the upper drive unit 120 is configured to drive the tubes 140 in three distinct movements: (i) radially inward (e.g., from the outer slots 354 to the inner slots 374) via rotation of the outer cam rings 352 of the outer assembly 350; (ii) radially outward (e.g., from the inner slots 374 to the outer slots 354) via rotation of the inner cam ring 372 of the inner assembly 370; and (iii) circumferentially via rotation of the inner assembly 370.
• these movements can be mechanically independent and a system controller (not pictured; e.g., a digital computer) can receive input from a user via a user interface indicating one or more operating parameters for these movements as well as the movement of the mandrel 102 ( Figure 1).
• the system controller can drive each of the four motors in the drive units 120, 130 (e.g., the outer cam ring motors 358, the inner cam ring motor 378, and the inner assembly motor 375) with closed loop shaft rotation feedback.
• the system controller can relay the parameters to the various motors (e.g., via a processor), thereby allowing manual and/or automatic control of the movements of the tubes 140 and the mandrel 102 to control formation of the braid 105.
• the system 100 can be parametric and many different forms of braid can be made without modification of the system 100.
• the various motions of the drive units 120, 130 are mechanically sequenced such that turning a single shaft indexes the drive units 120, 130 through an entire cycle.
• Figure 4A is a top view
• Figure 4B is an enlarged top view, of an embodiment of the outer assembly 350 of the upper drive unit 120.
• the upper plate 351a and the first outer cam ring 352a are not pictured to more clearly illustrate the operation of the outer assembly 350.
• the lower plate 351b has an inner edge 463 that defines a central opening 464.
• a plurality of wall portions 462 are arranged circumferentially around the lower plate 351b and extend radially inward beyond the inner edge 463 of the lower plate 351b.
• Each pair of adjacent wall portions 462 defines one of the outer slots 354 in the central opening 464.
• the wall portions 462 can be fastened to the lower plate 351b (e.g., using bolts, screws, welding, etc.) or integrally formed with the lower plate 351b. In other embodiments, all or a portion of the wall portions 462 can be on the upper plate 351 a rather than the lower plate 351b of the outer assembly 350.
• the second outer cam ring 352b includes an inner surface 465 having a periodic (e.g., oscillating) shape including a plurality of peaks 467 and troughs 469.
• the inner surface 465 has a smooth sinusoidal shape, while in other embodiments, the inner surface 465 can have other periodic shapes such as a saw-tooth shape.
• the second outer cam ring 352b is rotatably coupled to the lower plate 351b such that the second outer cam ring 352b and the lower plate 351b can rotate with respect to each other.
• the rotatable coupling comprises a plurality of bearings disposed in a first circular channel (obscured in Figures 4A in 4B) formed between the lower plate 351b and the second outer cam ring 352b.
• the second outer cam ring 352b includes a second circular channel 461 for rotatably coupling the second outer cam ring 352b to the first outer cam ring 352a via a plurality of bearings.
• the first circular channel can be substantially identical to the second circular channel 461.
• the first outer cam ring 352a can be substantially identical to the second outer cam ring 352b.
• the outer drive members 356 are positioned in between adjacent wall portions 462.
• Each of the outer drive members 356 is identical, although alternating ones of the outer drive members 356 are oriented differently within the outer assembly 350.
• adjacent ones of the outer drive members 356 can be flipped vertically relative to a plane defined by the lower plate 351b.
• the outer drive members 356 each comprise a body portion 492 coupled to a push portion 494.
• the push portions 494 are configured to engage (e.g., contact and push) tubes positioned within the outer slots 354.
• the body portions 492 further comprise a stepped portion 491 that does not engage the outer cam rings 352, and an extension portion 493 that engages only one of the outer cam rings 352.
• a first set of outer drive members 456a have an extension portion 493 that continuously contacts the inner surface 465 of the second outer cam ring 352b, but does not contact an inner surface of the first outer cam ring 352a.
• the extension portions 493 of the first set of outer drive members 456a do not contact the inner surface of the first outer cam ring 352a as they extend below the first outer cam ring 352a.
• a second set of outer drive members 456b have extension portions 493 that continuously contact the inner surface of the first outer cam ring 352a, but do not contact the second outer cam ring 352b.
• the extension portions 493 of the second set of outer drive members 456b do not contact the inner surface 465 of the second outer cam ring 352b as they extend above the second outer cam ring 352b.
• each of the outer cam rings 352 is configured to drive only one set (e.g., half) of the outer drive members 356.
• the outer drive members 356 can further include bearings 495 or other suitable mechanisms for providing a smooth coupling between the outer drive members 356 and the outer cam rings 352.
• the first set of outer drive members 456a can be coupled to the lower plate 351b in between alternating, adjacent pairs of the wall portions 462.
• the second set of outer drive member 456b can be coupled to the upper plate 351 a and positioned in between alternating, adjacent pairs of the wall portions 462 when the outer assembly 350 is assembled (e.g., when the upper plate 351 a is coupled to the lower plate 351b).
• the same mounting system can be used for each of the outer drive members 356.
• the outer drive members 356 can be slidably coupled to a frame 496 that is attached to one of the upper or lower plates 351 a, 351b by a plurality of screws 497. In other embodiments, all of the outer drive members 356 can be attached (e.g., via the frame 496 and screws 497) to the lower plate 351b or the upper plate 351 a.
• a biasing member 498 e.g., a spring
• the outer drive members 356 are driven radially inward by rotation of the periodic inner surfaces of the outer cam rings 352, and returned radially outward by the biasing members 498.
• each of the outer drive members are driven radially inward by rotation of the periodic inner surfaces of the outer cam rings 352, and returned radially outward by the biasing members 498.
• the troughs 469 of the inner surface 465 of the second outer cam ring 352b are aligned with the first set of outer drive members 456a.
• the extension portions 493 of the outer drive members 356 are at or nearer to the troughs 469 than the peaks 467 of the inner surface 465.
• rotation of the second outer cam ring 352b moves the peaks 467 of the inner surface 465 into radial alignment with the first set of outer drive members 456a.
• the extension portions 493 move radially inward as the inner surface 465 rotates from trough 469 to peak 467.
• the second outer cam ring 352b rotates to move the troughs 469 into radial alignment with the first set of outer drive members 456a.
• the radially outward biasing force of the biasing members 498 retracts the first set of outer drive members 456a into the space provided by the troughs 469.
• the operation of the second set of outer drive members 456b and the first outer cam ring 352a can be carried out in a substantially similar or identical manner.
• FIG. 5 is a top view of the inner assembly 370 of the upper drive unit 120.
• the upper plate 371a is not pictured to more clearly illustrate the operation of the inner assembly 370.
• the lower plate 371b has an outer edge 583
• the inner assembly 370 includes a plurality of wall portions 582 arranged circumferentially about the lower plate 371b and extending radially outward beyond the outer edge 583.
• Each pair of adjacent wall portions 582 defines one of the inner slots 374.
• the wall portions 582 can be fastened to the lower plate 371b (e.g., using bolts, screws, welding, etc.) or integrally formed with the lower plate 371b. In other embodiments, at least some of the wall portions 582 are on the upper plate 371a rather than the lower plate 371b of the inner assembly 370.
• the inner cam ring 372 includes an outer surface 585 having a periodic (e.g., oscillating) shape including a plurality of peaks 587 and troughs 589.
• the outer surface 585 has a saw-tooth shape, while in other embodiments, the outer surface 585 can have other periodic shapes such as a smooth sinusoidal shape.
• the inner cam ring 372 is rotatably coupled to the lower plate 371b by, for example, a plurality of ball bearings disposed in a first circular channel (obscured in the top view of Figure 5) formed between the lower plate 371b and the inner cam ring 372.
• the inner cam ring 372 includes a second circular channel 581 for rotatably coupling the inner cam ring 372 to the upper plate 371a via, for example, a plurality of ball bearings.
• the first circular channel can be substantially identical to the second circular channel 581.
• the inner cam ring 372 can accordingly rotate with respect to the upper and lower plates 371 a and 371b.
• each of the inner drive members 376 is identical, and the inner drive members 376 can be identical to the outer drive members 356 ( Figures 4A and 4B).
• each of the inner drive members 376 can have a body 492 including a stepped portion 491 and an extension portion 493, and the inner drive members 376 can each be slidably coupled to a frame 496 mounted to the lower plate 371b.
• biasing members 498 extending between each inner drive member 376 and their corresponding frame 496 exert a radially inward biasing force against the inner drive members 376.
• the extension portions 493 of the inner drive members 376 continuously contact the outer surface 585 of the inner cam ring 372.
• rotation of the outer periodic surface 585 drives the inner drive members 376 radially outward, while the biasing members 498 retract the inner drive members 376 radially inward.
• the inner drive members 376 are in a radially retracted position.
• the troughs 589 of the outer surface 585 of the inner cam ring 372 are radially aligned with the inner drive members 376 such that the extension portions 593 of the inner drive members 376 are at or nearer to the troughs 589 than the peaks 587 of the outer surface 585.
• the inner cam ring 372 rotates to move the peaks 587 of the outer surface 585 into radial alignment with the inner drive members 376. Since the biasing members 498 urge the extension portions 493 into continuous contact with the outer surface 585, the inner drive members 376 are continuously forced radially inward as the outer surface 585 rotates from trough 589 to peak 587. To subsequently return the inner drive members 576 to the radially retracted position, the inner cam ring 372 is rotated to move the troughs 589 into radial alignment with the inner drive members 576. As this rotation occurs, the radially inward biasing force provided by the biasing members 598 inwardly retracts the inner drive members 376 into the space provided by the troughs 589.
• each of the drive members in the system 100 is actuated by the rotation of a cam ring that provides a consistent and synchronized actuation force to all of the drive members.
• a cam ring that provides a consistent and synchronized actuation force to all of the drive members.
• filaments are actuated individually or in small sets by separately controlled actuators, if one actuator is out of synchronization with another, there is a possibility of tangling of filaments.
• FIG 6 is an enlarged isometric view of a portion of the upper drive unit 120 shown in Figure 3 that illustrates the synchronous (e.g., reciprocal) action of the assemblies 350, 370.
• the upper plate 351a of the outer assembly 350 and the upper plate 371 a of the inner assembly 370 are not shown in Figure 6 to more clearly illustrate the operation of these components.
• all of the tubes 140 are positioned in the outer slots 354 of the outer assembly 350. Accordingly, each of the outer drive members 356 is in a retracted position so that there is space for the tubes 140 in the outer slots 354.
• the troughs 469 (partially obscured; illustrated in Figures 4A and 4B) of the inner surface 465 of the second outer cam ring 352b are radially aligned with the first set of outer drive members 456a
• troughs 669 of a periodic inner surface 665 of first outer cam ring 352a are radially aligned with the second set of outer drive members 456b
• the biasing members 498 coupled to the outer drive members 356 have a minimum length (e.g., a fully compressed position).
• the inner drive members 376 are in a fully extended position in which the inner drive members 376 are in contact with the outer surface 585 of the inner cam ring 372 at or nearer to the peaks 587 of the outer surface 585 than the troughs 589.
• the biasing members 498 coupled to the inner drive members 376 have a maximum length (e.g., a fully expanded position).
• first set of outer drive members 456a are radially aligned with the inner slots 374. In this position the first set of outer drive members
• the second outer cam ring motor 358b can move the tubes 140 in the outer slots 354 corresponding to the first set of outer drive members 456a to the inner slots 374. To do so, the second outer cam ring motor 358b
• Figure 3 can be actuated to rotate (e.g., either clockwise or counterclockwise) the second outer cam ring 352b and thereby align the peaks 467 of the inner surface 465 with the first set of outer drive members 456a.
• the inner surface 465 accordingly drives the first set of outer drive members 456a radially inward.
• the inner cam ring motor 378 can be actuated to rotate the inner cam ring 372 (e.g., in the counterclockwise direction) to align the troughs 589 of the outer surface 585 of the inner cam ring 372 with the inner drive members
• the inner drive members 376 retract a corresponding amount to maintain the space for the tubes 140, and vice versa. This keeps the tubes 140 moving in a discrete, predictable pattern determined by a control system of the system 100.
• FIG. 7 is an isometric view of the lower drive unit 130 shown in Figure 1 configured in accordance with embodiments of the present technology.
• the lower drive unit 130 has components and functions that are substantially the same as or identical to the upper drive unit 120 described in detail above with reference to Figures 3-6.
• the lower drive unit 130 includes an outer assembly 750 and an inner assembly 770.
• the outer assembly 750 can include (i) outer slots, (ii) outer drive members aligned with and/or positioned within corresponding outer slots, and (iii) an outer drive mechanism configured to move the outer drive members radially inward through the outer slots, etc.
• the inner assembly 770 can include (i) inner slots, (ii) inner drive members aligned with and/or positioned within corresponding inner slots, and an inner drive mechanism configured to move the inner drive members radially outward through the inner slots, etc.
• the inner drive mechanisms (e.g., inner cam rings) of the drive units 120, 130 move in a substantially identical sequence both spatially and temporally to drive the upper portion and lower portion of each individual tube 140 along the same or a substantially similar spatial path.
• the outer drive mechanisms (outer cam rings) of the drive units 120, 130 move in a substantially identical sequence both spatially and temporally.
• the drive units 120, 130 are synchronized using a mechanical connection.
• jackshafts 713 can mechanically couple corresponding components of the inner and outer drive mechanisms of the drive units 120, 130.
• the jackshafts 713 mechanically couple the first outer cam ring 352a of the upper drive unit 120 to a matching first outer ring cam in the lower drive unit 130, and the second outer cam ring 352b of the upper drive unit 120 to a matching second outer ring cam in the lower drive unit 130.
• Jackshafts 713 can similarly couple the inner cam ring 372 and the inner assembly 370 (e.g., for rotating the inner assembly 370) to corresponding components in the lower drive unit 130.
• Including separate motors on both drive units 120, 130 avoids torsional whip in the jackshafts while assuring motion synchronization between the drive units 120, 130.
• the motors in one of the drive 120, 130 are closed loop controlled, while the motors in the other of the drive units 120, 130 act as slaves.
• the drive units 120, 130 move one of two sets of tubes 140 (and the filaments positioned within those tubes) at a time. Each set consists of alternating ones of the tubes 140 and therefore one half of the total number of tubes 140.
• the drive units 120, 130 move a set, the set is moved (i) radially inward, (ii) rotated past the other set, and then (iii) moved radially outward. The sequence is then applied to the other set, with rotation happening in the opposite direction.
• Figures 8A-8H are schematic views more particularly showing the movement of six tubes within the upper drive unit 120 at various stages in a method of forming a braided structure (e.g., the braid 105) in accordance with embodiments of the present technology. While reference is made to the movement of the tubes within the upper drive unit 120, the illustrated movement of the tubes is substantially the same or even identical in the lower drive unit 130. Moreover, while only six tubes are shown in Figures 8A-8H for ease of explanation and understanding, one skilled in the art will readily understand that the movement of the six tubes is representative of any number of tubes (e.g., 24 tubes, 48 tubes, 96 tubes, or other numbers of tubes).
• the six tubes are individually labeled 1-6 and are all initially positioned in separate outer slots 354 of the outer assembly 350, labeled A-F, respectively.
• a first set of tubes 840a (including tubes 1, 3, and 5) positioned in the outer slots 354 labeled A, C, E are radially aligned with corresponding inner slots 374 labeled X-Z of the inner assembly 370.
• a second set of tubes 840b (including tubes 2, 4, and 6) positioned in the outer slots 354 labeled B, D, and F are not radially aligned with any of the inner slots 374 of the inner assembly 370.
• the reference numerals A-F for the outer slots 354, X-Z for the inner slots 374, and 1-6 for the tubes are reproduced in each of Figures 8A-8H in order to illustrate the relative movement of these components.
• the first set of tubes 840a is moved radially inward from the outer slots 354 of the outer assembly 350 to the inner slots 374 of the inner assembly 370.
• the outer drive members 356 aligned with the first set of tubes 840a move radially inward and drive the first set of tubes 840a radially inward into the inner slots 374.
• the inner drive members 376 can be retracted radially inward through the inner slots 374 to provide space for the first set of tubes 840a to be moved into the inner slots 374. In this manner, the outer assembly 350 and inner assembly 370 move in concert with each other to manipulate the space provided for the first set of tubes 840a.
• the inner assembly 370 rotates in a first direction (e.g., in the clockwise direction indicated by the arrow CW) to align the inner slots 374 with a different set of the outer slots 354.
• the inner slots 374 are aligned with a different set of outer slots 354 that are two slots away.
• this step passes the filaments in the first set of tubes 840a under the filaments in the second set of tubes 840b.
• the first set of tubes 840a is moved radially outward from the inner slots 374 of the inner assembly 370 to the outer slots 354 of the outer assembly 350.
• the inner drive members 376 move radially outward through the inner slots 374 and drive the first set of tubes 840a radially outward into the outer slots 354 aligned with the inner slots 374.
• the outer drive members 356 are retracted radially outward through the aligned outer slots 354 to provide space for the first set of tubes 840a to be moved into the outer slots 354.
• the second set of tubes 840b is stationary during each step in which the first set of tubes 840a is moved.
• the inner assembly 370 is rotated in a second direction (e.g., in the counterclockwise direction indicated by the arrow CCW) to align the inner slots 374 with different outer slots 354— i.e., those holding the second set of tubes 840b.
• the inner assembly 370 can be rotated in the first direction to align the inner slots 374 with different outer slots 354.
• the inner assembly 370 is rotated to align each inner slot 374 with a different outer slot 354 that is one slot away (e.g., an adjacent outer slot 354).
• the outer drive members 356 aligned with the second set of tubes 840b move radially inward through the outer slots 354 and drive the second set of tubes 840b radially inward into the inner slots 374 while, at the same time, the inner drive members 376 retract radially inward through the inner slots 374 to provide space for the second set of tubes 840b to be moved into the inner slots 374.
• the inner assembly 370 is rotated in the second direction (e.g., in the clockwise direction indicated by the arrow CCW) to align the inner slots 374 with a different set of the outer slots 354.
• the inner assembly 370 is rotated to align each inner slot 374 with a different outer slot 354 that is two slots away.
• the inner slot 374 labeled Y was previously aligned with the outer slot 354 labeled D ( Figure 8E)
• this step passes the filaments in the second set of tubes 840b under the filaments in the first set of tubes 840a.
• the second set of tubes 840b is moved radially outward from the inner slots 374 of the inner assembly 370 to the outer slots 354 of the outer assembly 350.
• the inner drive members 376 move radially outward through the inner slots 374 and drive the first set of tubes 840a radially outward into the outer slots 354 aligned with the inner slots 374.
• the outer drive members 356 can be retracted radially outward through the outer slots 354 in order to provide space for the first set of tubes 840a to be moved into the outer slots 354.
• the first set of tubes 840a is stationary during each step in which the second set of tubes 840b is moved.
• the inner assembly 370 rotates in the first direction (e.g., in the clockwise direction indicated by the arrow CCW) to align the inner slots 374 with different ones of the outer slots 354— i.e., those holding the first set of tubes 840a.
• the inner assembly 370 rotates in the second direction to align the inner slots 374 with different ones of the outer slots 354.
• rotation of the inner assembly 370 aligns the inner slots 374 with a different set of outer slots 354 that are one slot away (e.g., an adjacent outer slot 354).
• each tube in the first set of tubes 840a has been rotated in the first direction (e.g., rotated two outer slots 354 in the clockwise direction) relative to the initial position shown in Figure 8A
• each tube in the second set of tubes 840b has been rotated in the second direction (e.g., rotated two outer slots 354 in the counterclockwise direction) relative to the initial position of Figure 8A.
• Figure 9 is a screenshot of a user interface 900 that can be used to control the system 100 (Figure 1) and the characteristics of the resulting braid 105 formed on the mandrel 102.
• a plurality of clickable, pushable, or otherwise engageable buttons, indicators, toggles, and/or user elements is shown within the user interface 900.
• the user interface 900 can include a plurality of elements each indicating a desired and/or expected characteristic for the resulting braid 105.
• characteristics can be selected for one or more zones (e.g., the 7 illustrated zones) each corresponding to a different vertical portion of the braid 105 formed on the mandrel 102.
• elements 910 can indicate a length for the zone along the length of the mandrel or braid (e.g., in cm)
• elements 920 can indicate a number of picks (a number of crosses) per cm
• elements 930 can indicate a pick count (e.g., a total pick count)
• elements 940 can indicate a speed for the process (e.g., in picks formed per minute)
• elements 950 can indicate a braiding wire count.
• some or all of the other characteristics may be constrained or automatically selected. For example, a user input of a certain number of "picks per cm" and zone "length” may constrain or determine the possible number of "picks per cm.
• the user interface can further include selectable elements 960 for pausing of the system 100 after the braid 105 has been formed in a certain zone, and selectable elements 970 for keeping the mandrel stationary during the formation of a particular zone (e.g., to permit manual jogging of the mandrel 102 rather than automatic).
• the user interface can include elements 980a and 980b for jogging the table, elements 985a and 985b for jogging (e.g., raising or lowering) the mandrel 102 up or down, respectively, elements 990a and 990b for loading a profile (e.g., a set of saved braid characteristics) and running a selected profile, respectively, and an indicator 995 for indicating that a run (e.g., all or a portion of a braiding process) is complete.
• a profile e.g., a set of saved braid characteristics
• an indicator 995 for indicating that a run (e.g., all or a portion of a braiding process) is complete.
• FIG. 10 is an enlarged view of the mandrel 102 and the braid 105 formed thereon.
• the braid 105 or mandrel 102 can include a first zone Zl, a second zone Z2, and a third zone Z3 each having different characteristics.
• the first zone Zl can have a higher pick count than the second and third zones Z2 and Z3, and the second zone Z2 can have a higher pick count than third zone Z3.
• the braid 105 can therefore have a varying flexibility— as well as pore size— in each zone.
• a braiding system comprising:
• a plurality of tubes extending between the upper drive unit and the lower drive unit, wherein individual tubes are configured to receive individual filaments, and wherein the upper drive unit and the lower drive unit act against the tubes in synchronization.
• the braiding system of example 1 wherein the tubes are constrained within the upper and lower drive units, and wherein the upper and lower drive units act against the tubes to (i) drive the tubes radially inward, (ii) drive the tubes radially outward, and (iii) rotate the tubes with respect to the mandrel.
• the tubes include a first set of tubes and a second set of tubes, and wherein the upper and lower drive units act against the tubes to rotate the first set of tubes relative to the second set of tubes.
• the upper drive unit comprises (a) an outer assembly including (i) outer slots, (ii) outer drive members, and (iii) an outer drive mechanism configured to move the outer drive members, and (b) an inner assembly including (i) inner slots, (ii) inner drive members, and (iii) an inner drive mechanism configured to move the inner drive members;
• the lower drive unit comprises (a) an outer assembly including (i) outer slots, (ii) outer drive members, and (iii) an outer drive mechanism configured to move the outer drive members, and (b) an inner assembly including (i) inner slots, (ii) inner drive members, and (iii) an inner drive mechanism configured to move the inner drive members; and
• the outer slots of the upper drive unit are radially aligned with the outer drive members of the upper drive unit and the outer drive mechanism of the upper drive unit is configured to move the outer drive members radially inward through the outer slots;
• the inner slots of the upper drive unit are radially aligned with the inner drive members of the upper drive unit and the inner drive mechanism of the upper drive unit is configured to move the inner drive members radially outward through the inner slots;
• the outer slots of the lower drive unit are radially aligned with the outer drive members of the lower drive unit and the outer drive mechanism of the lower drive unit is configured to move the outer drive members radially inward through the outer slots;
• the inner slots of the lower drive unit are radially aligned with the inner drive members of the lower drive unit and the inner drive mechanism of the lower drive unit is configured to move the inner drive members radially outward through the inner slots.
• the outer assembly of the upper drive unit further comprises outer biasing members coupled to corresponding one of the outer drive members and configured to apply a radially outward force to the outer drive members;
• the inner assembly of the upper drive unit further comprises inner biasing members coupled to corresponding one of the inner drive members and configured to apply a radially inward force to the inner drive members;
• the outer assembly of the lower drive unit further comprises outer biasing members coupled to corresponding one of the outer drive members and configured to apply a radially outward force to the outer drive members; and the inner assembly of the lower drive unit further comprises inner biasing members coupled to corresponding one of the inner drive members and configured to apply a radially inward force to the inner drive members.
• the inner assembly of the upper drive unit is rotatable relative to the outer assembly of the upper drive unit;
• the inner assembly of the lower drive unit is rotatable relative to the outer assembly of the lower drive unit
• the inner assemblies of the lower and upper drive unit are configured to rotate in synchronization.
• the outer drive mechanism of the upper drive unit comprises (i) a first upper outer cam ring configured to move a first set of the outer drive members of the upper drive unit radially inward and (ii) a second upper outer cam ring configured to move a second set of the outer drive members of the upper drive unit radially inward;
• the inner drive mechanism of the upper drive unit comprises an upper inner cam ring configured to move the inner drive members of the upper drive unit radially outward;
• the outer drive mechanism of the lower drive unit comprises (i) a first lower outer cam ring configured to move a first set of the outer drive members of the lower drive unit radially inward and (ii) a second lower outer cam ring configured to move a second set of the outer drive members of the lower drive unit radially inward; and
• the inner drive mechanism of the lower drive unit comprises a lower inner cam ring configured to move the inner drive members of the lower drive unit radially outward.
• the first upper outer cam ring and the first lower outer cam ring are substantially identical and synchronized to move together;
• the second upper outer cam ring and second lower outer cam ring are substantially identical and synchronized to move together;
• the first set of the outer drive members of the upper drive unit comprises alternating ones of the outer drive members
• the second set of the outer drive members of the upper drive unit comprises different alternating ones of the outer drive members
• the first set of the outer drive members of the lower drive unit comprises alternating ones of the outer drive members
• the second set of the outer drive members of the lower drive unit comprises different alternating ones of the outer drive members
• the first upper outer cam ring is substantially identical to the second upper outer cam ring and rotatably coupled to the second upper outer cam ring;
• the first lower outer cam ring is substantially identical to the second lower outer cam ring and rotatably coupled to the second lower outer cam ring.
• the first upper outer cam ring has a radially-inward facing surface with a periodic shape that is in continuous contact with the first set of the outer drive members of the upper drive unit;
• the second upper outer cam ring has a radially-inward facing surface with a periodic shape that is in continuous contact with the second set of the outer drive members of the upper drive unit;
• the upper inner cam ring has a radially-outward facing surface with a periodic shape that is in continuous contact with the inner drive members of the upper drive unit;
• the first lower outer cam ring has a radially-inward facing surface with a periodic shape that is in continuous contact with the first set of the outer drive members of the lower drive unit;
• the second upper outer cam ring has a radially-inward facing surface with a periodic shape that is in continuous contact with the second set of the outer drive members of the lower drive unit; and the lower inner cam ring has a radially-outward facing surface with a periodic shape that is in continuous contact with the inner drive members of the lower drive unit.
• the outer drive mechanism of the upper drive unit comprises an upper outer cam ring configured to move the outer drive members of the upper drive unit radially inward;
• the inner drive mechanism of the upper drive unit comprises an upper inner cam ring configured to move the inner drive members of the upper drive unit radially outward;
• the outer drive mechanism of the lower drive unit comprises a lower outer cam ring configured to move the outer drive members of the lower drive unit radially inward;
• the inner drive mechanism of the lower drive unit comprises a lower inner cam ring configured to move the inner drive members of the lower drive unit radially outward.
• a braiding system comprising:
• an outer assembly including (i) a central opening, (ii) a first outer cam, (iii) a second outer cam positioned adjacent to the first outer cam and coaxially aligned with the first outer cam along a longitudinal axis, (iv) outer slots extending radially relative to the longitudinal axis, and (v) an outer drive mechanism;
• an inner assembly in the central opening of the outer assembly including (i) an inner cam, (ii) inner slots extending radially relative to the longitudinal axis, (iii) and an inner drive mechanism;
• outer drive mechanism is configured to (i) rotate the first outer cam to drive a first set of the tubes radially inward from the outer slots to the inner slots and (ii) rotate the second outer cam to drive a second set of the tubes radially inward from the outer slots to the inner slots, and
• the inner drive mechanism is configured to (i) rotate the inner cam to move either the first or second set of tubes radially outward from the inner slots to the outer slots and (ii) rotate the inner assembly relative to the outer assembly.
• each filament extends radially from the mandrel to an individual tube such that an end portion of the filament is within the individual tube.
• a method of forming a tubular braid comprising:
• driving the second cam to move the first set of tubes radially outward includes moving the first set of tubes to a radial position in which each tube in the first and second set of tubes is equally spaced radially from the central axis; and driving the second cam to move the second set of tubes radially outward includes moving the second set of tubes to the radial position.
• driving the first cam to move the first set of tubes radially inward includes engaging an inner surface of the first cam with first drive members that engage the first set of tubes;
• driving the second cam to move the first set of tubes radially outward includes engaging an outer surface of the second cam with second drive members, the second drive members engaging the first set of tubes;
• driving the third cam to move the second set of tubes radially inward includes engaging an inner surface of the third cam with third drive members that engage the second set of tubes;
• driving the second cam to move the second set of tubes radially outward includes engaging the outer surface of the second cam with the second drive members, the second drive members engaging the second set of tubes.
• a method of forming a tubular braid comprising:
• a braiding system comprising:
• the upper drive unit comprises (a) an outer assembly including (i) outer slots, (ii) outer drive members, and (iii) an outer drive mechanism configured to move the outer drive members, and (b) an inner assembly including (i) inner slots, (ii) inner drive members, and (iii) an inner drive mechanism configured to move the inner drive members;
• the lower drive unit comprises (a) an outer assembly including (i) outer slots, (ii) outer drive members, and (iii) an outer drive mechanism configured to move the outer drive members, and (b) an inner assembly including (i) inner slots, (ii) inner drive members, and (iii) an inner drive mechanism configured to move the inner drive members; and
• the outer drive mechanism of the upper drive unit comprises an upper outer cam ring configured to move the outer drive members of the upper drive unit radially inward;
• the inner drive mechanism of the upper drive unit comprises an upper inner cam ring configured to move the inner drive members of the upper drive unit radially outward;
• the outer drive mechanism of the lower drive unit comprises a lower outer cam ring configured to move the outer drive members of the lower drive unit radially inward; and the inner drive mechanism of the lower drive unit comprises a lower inner cam ring configured to move the inner drive members of the lower drive unit radially outward.
• a mechanism for braiding comprising:
• a first disc cam with a central opening and defining a plane
• a second disc cam with a central opening and defining a plane that can be rotated relative to the first disc cam
• a mandrel extending concentrically with respect to the first and second disc cams and generally perpendicular to the planes of the first and second disc cams and defining an axis;
• each tube having an upper end and a lower end, and the upper ends of the tubes are arrayed in a circle about the mandrel;
• a drive mechanism that rotates at least one of the disc cams thus moving a half of the tubes in the radial direction into or out of the slots of the inner or outer disc; a drive mechanism that rotates at least one slotted disc to move half of the tubes relative to the other half of the tubes;
• each filament having a first end and second end, the first end of each filament extending from the mandrel in a radial direction and then individually within a tube, wherein the filaments are braided about the mandrel when the tubes are moved through a series of radial and rotational movements driven by movement of the discs.
• outer and inner slotted discs define a plurality of radial spaces, and individual radial spaces are configured to constrain an individual tube of the plurality of tubes, and wherein synchronized movement of the outer and inner slotted discs move the tubes in an over-under weave.
• a method of forming a tubular braid of filaments comprising;
• a braiding mechanism comprising a plurality of filaments, a plurality of tubes equal to the number of filaments where each tube continuously engages a filament, a mandrel, a plurality of discs configured to move the tubes and at least one drive mechanism configured to move the discs thus driving movement of the tubes and filaments to form a braid about the mandrel comprising the following steps:

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